Surface porosity during vacuum bag-only prepreg processing: Causes and mitigation strategies

In this study, we employ a parametric approach coupled with surface analysis to identify the source(s) of surface porosity and to develop effective mitigation strategies. Results confirmed that surface porosity was primarily associated with air that was trapped at the tool–prepreg interface during layup. The magnitude and distribution of surface porosity was affected by multiple parameters, including vacuum hold time, freezer and out time, and material and process modifications that affect air evacuation. The results indicated that prepreg out time (and thus tack) and vacuum quality were the primary drivers of surface porosity; for example, surface porosity decreased by 83% after just four days of out time and by 99% after 14 days of out time. These factors were used to formulate guidelines to mitigate surface porosity by (a) increasing the driving force for air evacuation and/or (b) increasing the permeability of the tool–prepreg interface.